WO2019010323A1 - Collecteur de courant monopièce pour cellule de batterie - Google Patents

Collecteur de courant monopièce pour cellule de batterie Download PDF

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Publication number
WO2019010323A1
WO2019010323A1 PCT/US2018/040943 US2018040943W WO2019010323A1 WO 2019010323 A1 WO2019010323 A1 WO 2019010323A1 US 2018040943 W US2018040943 W US 2018040943W WO 2019010323 A1 WO2019010323 A1 WO 2019010323A1
Authority
WO
WIPO (PCT)
Prior art keywords
leg
current collector
connecting portion
battery cell
lithium ion
Prior art date
Application number
PCT/US2018/040943
Other languages
English (en)
Inventor
Xugang Zhang
John P. Dinkelman
Rengaraj Balakrishnan
David W. Heatherington
Original Assignee
Johnson Controls Technology Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Controls Technology Company filed Critical Johnson Controls Technology Company
Publication of WO2019010323A1 publication Critical patent/WO2019010323A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/536—Electrode connections inside a battery casing characterised by the method of fixing the leads to the electrodes, e.g. by welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/538—Connection of several leads or tabs of wound or folded electrode stacks
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present disclosure relates generally to the field of batteries and battery modules. More specifically, the present disclosure relates to a current collector for use in a battery cell.
  • a vehicle that uses one or more battery systems for providing all or a portion of the motive power for the vehicle can be referred to as an xEV, where the term "xEV” is defined herein to include all of the following vehicles, or any variations or combinations thereof, that use electric power for all or a portion of their vehicular motive force.
  • xEVs include electric vehicles (EVs) that utilize electric power for all motive force.
  • EVs electric vehicles
  • hybrid electric vehicles (HEVs) also considered xEVs, combine an internal combustion engine propulsion system and a battery-powered electric propulsion system, such as 48 Volt (V) or 130V systems.
  • the term HEV may include any variation of a hybrid electric vehicle.
  • full hybrid systems may provide motive and other electrical power to the vehicle using one or more electric motors, using only an internal combustion engine, or using both.
  • mild hybrid systems MHEVs
  • MHEVs disable the internal combustion engine when the vehicle is idling and utilize a battery system to continue powering the air conditioning unit, radio, or other electronics, as well as to restart the engine when propulsion is desired.
  • the mild hybrid system may also apply some level of power assist, during acceleration for example, to supplement the internal combustion engine.
  • Mild hybrids are typically 96V to 130V and recover braking energy through a belt or crank integrated starter generator.
  • a micro- hybrid electric vehicle also uses a "Stop-Start" system similar to the mild hybrids, but the micro-hybrid systems of a mHEV may or may not supply power assist to the internal combustion engine and operates at a voltage below 60V.
  • mHEVs typically do not technically use electric power provided directly to the crankshaft or transmission for any portion of the motive force of the vehicle, but an mHEV may still be considered as an xEV since it does use electric power to supplement a vehicle's power needs when the vehicle is idling with internal combustion engine disabled and recovers braking energy through an integrated starter generator.
  • a plug-in electric vehicle is any vehicle that can be charged from an external source of electricity, such as wall sockets, and the energy stored in the rechargeable battery packs drives or contributes to drive the wheels.
  • PEVs are a subcategory of EVs that include all-electric or battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and electric vehicle conversions of hybrid electric vehicles and
  • xEVs as described above may provide a number of advantages as compared to more traditional gas-powered vehicles using only internal combustion engines and traditional electrical systems, which are typically 12V systems powered by a lead acid battery.
  • xEVs may produce fewer undesirable emission products and may exhibit greater fuel efficiency as compared to traditional internal combustion vehicles and, in some cases, such xEVs may eliminate the use of gasoline entirely, as is the case of certain types of EVs or PEVs.
  • battery modules may include one or more battery cells each having various electrically conductive components that allow for electrical pathways to be established between electrochemical materials of the battery cells and an external load.
  • the components forming the electrical pathways may carry relatively large amounts of electrical current. Further, certain of the components - particularly those located internal to the battery cells - may be placed under stresses resulting from changes in temperature, pressure fluctuations, and so forth. The components may be connected using various processes such as fastening and/or bonding, and the joints that are correspondingly formed may be subject to these stresses. These and other stresses, when placed on the components and joints, can potentially cause structural instability and resulting degradation in performance of the battery cells. Accordingly, it is now recognized that there is a need for improved components and manufacturing processes associated with battery cells.
  • the present disclosure relates to a current collector for use in a lithium ion battery cell.
  • the current collector includes a first leg, a second leg, and a connecting portion between the first leg and the second leg and configured to be secured to a terminal of the lithium ion battery cell.
  • the first leg, the second leg, and the connecting portion are all manufactured from a single continuous piece of material.
  • the present disclosure also relates to a lithium ion battery cell.
  • the lithium ion battery cell includes an electrode assembly having an anode foil and a cathode foil.
  • the lithium ion battery cell also includes a current collector physically and electrically coupled to the electrode assembly via the anode foil or the cathode foil.
  • the current collector includes a first leg, a second leg, and a connecting portion disposed between the first and second legs, the connecting portion having a planar tab configured to connect to a surface of a terminal of the lithium ion battery cell.
  • the first leg, the second leg, and the connecting portion are manufactured from a single continuous piece of material.
  • the present disclosure further relates to a method of manufacturing a lithium ion battery cell, the lithium ion battery cell having a one-piece current collector having a first leg, a second leg, and a connecting portion formed from a single continuous piece of material.
  • the method includes attaching the one-piece current collector to an electrode foil of an electrode assembly via the first leg and the second leg, and attaching the one-piece current collector to one of a negative terminal or a positive terminal of the lithium ion battery cell via the connecting portion.
  • FIG. 1 is a perspective view of a vehicle having a battery system configured in accordance with present embodiments to provide power for various components of the vehicle, in accordance with an aspect of the present disclosure
  • FIG. 2 is a cutaway schematic view of an embodiment of the vehicle and the battery system of FIG. 1, in accordance with an aspect of the present disclosure
  • FIG. 3 is a perspective view of an embodiment of the battery system of FIG. 1, in accordance with an aspect of the present disclosure
  • FIG. 4 is a perspective view of a one-piece current collector coupled to a battery cell electrode assembly and battery terminal, in accordance with an aspect of the present disclosure
  • FIG. 5 is a perspective view of the one-piece current collector of FIG. 4, in accordance with an aspect of the present disclosure
  • FIG. 6 is a top plan view of the one-piece current collector of FIG. 4 in a flat configuration, in accordance with an aspect of the present disclosure
  • FIG. 7 is a front elevation view of the one-piece current collector of FIG. 4 in a folded configuration, in accordance with an aspect of the present disclosure
  • FIG. 8 is a side elevation view of the one-piece current collector of FIG. 4 in the folded configuration, in accordance with an aspect of the present disclosure
  • FIG. 9 is an underside perspective view of the one-piece current collector of FIG. 4 in the folded configuration, in accordance with an aspect of the present disclosure
  • FIG. 10 is an expanded cross-sectional elevation view of the one-piece current collector and the battery terminal of FIG. 4, in accordance with an aspect of the present disclosure
  • FIG. 11 is a partial bottom view of an embodiment of a weld between the one- piece current collector and the battery terminal, in accordance with an aspect of the present disclosure
  • FIG. 12 is a partial bottom view of another embodiment of a weld between the one-piece current collector and the battery terminal, in accordance with an aspect of the present disclosure.
  • FIG. 13 is an overhead view of an example configuration of a plurality of one- piece current collectors during a manufacturing process, in accordance with an aspect of the present disclosure.
  • battery cells may include current collectors that electrically couple electrodes of the battery cells to their respective terminals.
  • Certain current collectors may include, for example two components: a planar tab and an elongate strip folded into a substantially U-shaped configuration, which is coupled to the planar tab.
  • the planar tab is used for coupling to a terminal of the battery cell, while the elongate strip is used for coupling to either an anode or a cathode foil of an electrode assembly of the cell.
  • the planar tab is welded to the elongate strip.
  • the planar tab may be thinner than the elongate strip, which facilitates welding to the battery cell terminal.
  • assembling a two-piece negative current collector involves a first manufacturing step to create the planar tab and a second manufacturing step to create the elongate strip, and further involves a first weld to affix the planar tab to the elongate strip and a second weld to affix the planar tab to the battery cell terminal.
  • a current collector of the present disclosure may be manufactured as a single continuous piece of material.
  • the material may be an electrically conductive material, such as copper or aluminum.
  • the current collector is manufactured in a linear or flat first configuration, but is configured to be folded or bent into a folded second configuration that has a substantially U-shaped configuration.
  • Such a configuration of the current collector may simplify manufacturing and lower manufacturing costs associated with battery cells. Further, the one-piece configuration for the current collector may promote more stable operation of the battery cell relative to configurations where more than one piece is used, for example by avoiding structural imperfections that can result from multiple welding processes being performed on the current collector. Indeed, such benefits may translate to larger systems that incorporate multiple such battery cells, including battery systems that include one or more battery modules housing a plurality of battery cells. In this respect, the present disclosure relates to improved current collectors, battery cells that utilize the current collectors, and battery systems that utilize the battery cells.
  • the battery systems described herein may be used to provide power to various types of electric vehicles (xEVs) and other high voltage energy storage/expending applications (e.g., electrical grid power storage systems).
  • Such battery systems may include one or more battery modules, each battery module having a number of battery cells (e.g., lithium-ion (Li-ion) electrochemical cells) arranged and electrically interconnected to provide particular voltages and/or currents useful to power, for example, one or more components of an xEV.
  • battery modules in accordance with present embodiments may be incorporated with or provide power to stationary power systems (e.g., non-automotive systems).
  • FIG. 1 is a perspective view of an embodiment of a vehicle 10, which may utilize a regenerative braking system.
  • vehicle 10 which may utilize a regenerative braking system.
  • the techniques described herein are adaptable to other vehicles that capture/store electrical energy with a battery, which may include electric-powered and gas-powered vehicles.
  • the battery system 12 may be placed in a location in the vehicle 10 that would have housed a traditional battery system.
  • the vehicle 10 may include the battery system 12 positioned similarly to a lead-acid battery of a typical combustion-engine vehicle (e.g., under the hood of the vehicle 10).
  • the battery system 12 may be positioned to facilitate managing temperature of the battery system 12. For example, in some embodiments, positioning a battery system 12 under the hood of the vehicle 10 may enable an air duct to channel airflow over the battery system 12 and cool the battery system 12.
  • the battery system 12 includes an energy storage component 14 coupled to an ignition system 16, an alternator 18, a vehicle console 20, and optionally to an electric motor 22.
  • the energy storage component 14 may capture/store electrical energy generated in the vehicle 10 and output electrical energy to power electrical devices in the vehicle 10.
  • the battery system 12 may supply power to components of the vehicle's electrical system, which may include radiator cooling fans, climate control systems, electric power steering systems, active suspension systems, auto park systems, electric oil pumps, electric super/turbochargers, electric water pumps, heated windscreen/defrosters, window lift motors, vanity lights, tire pressure monitoring systems, sunroof motor controls, power seats, alarm systems, infotainment systems, navigation features, lane departure warning systems, electric parking brakes, external lights, or any combination thereof.
  • the energy storage component 14 supplies power to the vehicle console 20, a display 21 within the vehicle, and the ignition system 16, which may be used to start (e.g., crank) an internal combustion engine 24.
  • the energy storage component 14 may capture electrical energy generated by the alternator 18 and/or the electric motor 22.
  • the alternator 18 may generate electrical energy while the internal combustion engine 24 is running. More specifically, the alternator 18 may convert the mechanical energy produced by the rotation of the internal combustion engine 24 into electrical energy.
  • the electric motor 22 may generate electrical energy by converting mechanical energy produced by the movement of the vehicle 10 (e.g., rotation of the wheels) into electrical energy.
  • the energy storage component 14 may capture electrical energy generated by the alternator 18 and/or the electric motor 22 during regenerative braking.
  • the alternator 18 and/or the electric motor 22 are generally referred to herein as a regenerative braking system.
  • the energy storage component 14 may be electrically coupled to the vehicle's electric system via a bus 26.
  • the bus 26 may enable the energy storage component 14 to receive electrical energy generated by the alternator 18 and/or the electric motor 22.
  • bus 26 may enable the energy storage component 14 to output electrical energy to the ignition system 16 and/or the vehicle console 20.
  • the bus 26 may carry electrical power typically between 8-18 volts.
  • the energy storage component 14 may include multiple battery modules.
  • the energy storage component 14 includes a lead acid (e.g., a first) battery module 28 in accordance with present embodiments, and a lithium ion (e.g., a second) battery module 30, where each battery module 70, 72 includes one or more battery cells.
  • the energy storage component 14 may include any number of battery modules.
  • the first battery module 28 and the second battery module 30 are depicted adjacent to one another, they may be positioned in different areas around the vehicle.
  • the second battery module 30 may be positioned in or about the interior of the vehicle 10 while the first battery module 28 may be positioned under the hood of the vehicle 10.
  • the energy storage component 14 may include multiple battery modules to utilize multiple different battery chemistries.
  • the first battery module 28 may utilize a lead-acid battery chemistry and the second battery module 30 may utilize a lithium ion battery chemistry.
  • the first battery module 28 may utilize a lead-acid battery chemistry and the second battery module 30 may utilize a lithium ion battery chemistry.
  • the performance of the battery system 12 may be improved since the lithium ion battery chemistry generally has a higher coulombic efficiency and/or a higher power charge acceptance rate (e.g., higher maximum charge current or charge voltage) than the lead-acid battery chemistry. As such, the capture, storage, and/or distribution efficiency of the battery system 12 may be improved.
  • the battery system 12 may additionally include a control module 32. More specifically, the control module 32 may control operations of components in the battery system 12, such as relays (e.g., switches) within energy storage component 14, the alternator 18, and/or the electric motor 22.
  • relays e.g., switches
  • control module 32 may regulate amount of electrical energy captured/supplied by each battery module 28 or 30 (e.g., to de-rate and re-rate the battery system 12), perform load balancing between the battery modules 28 and 30, determine a state of charge of each battery module 28 or 30, determine temperature of each battery module 28 or 30, determine a predicted temperature traj ectory of either battery module 28 and 30, determine predicted life span of either battery module 28 or 30, determine fuel economy contribution by either battery module 28 or 30, determine an effective resistance of each battery module 28 or 30, control magnitude of voltage or current output by the alternator 18 and/or the electric motor 22, and the like.
  • the control module (e.g., unit) 32 may include one or more processors 34 and one or more memories 36.
  • the one or more processors 34 may include one or more application specific integrated circuits (ASICs), one or more field programmable gate arrays (FPGAs), one or more general purpose processors, or any combination thereof.
  • ASICs application specific integrated circuits
  • FPGAs field programmable gate arrays
  • general purpose processors or any combination thereof.
  • the processor 34 may perform computer-readable instructions related to the processes described herein.
  • the processor 34 may be a fixed-point processor or a floating-point processor.
  • the one or more memories 36 may include volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as readonly memory (ROM), optical drives, hard disc drives, or solid-state drives.
  • the control module 32 may include portions of a vehicle control unit (VCU) and/or a separate battery control module. Additionally, as depicted, the control module 32 may be included separate from the energy storage component 14, such as a standalone module. In other embodiments, the battery management system (BMS) may be included within the energy storage component 14.
  • VCU vehicle control unit
  • BMS battery management system
  • the control module 32 or the processor 34 may receive data from various sensors 38 disposed within and/or around the energy storage component 14.
  • the sensors 38 may include a variety of sensors for measuring current, voltage, temperature, and the like regarding the battery module 28 or 30.
  • the processor 34 may convert raw data into estimations of parameters of the battery modules 28 and 30.
  • the processor 34 may render the raw data into data that may provide an operator of the vehicle 10 with valuable information pertaining to operations of the battery system 12, and the information pertaining to the operations of the battery system 12 may be displayed on the display 21.
  • the display 21 may display various images generated by device 10, such as a GUI for an operating system or image data (including still images and video data).
  • the display 21 may be any suitable type of display, such as a liquid crystal display (LCD), plasma display, or an organic light emitting diode (OLED) display, for example. Additionally, the display 21 may include a touch-sensitive element that may provide inputs to the adjust parameters of the control module 32 or data processed by the processor 34.
  • LCD liquid crystal display
  • OLED organic light emitting diode
  • FIGS. 1 and 2 depict example systems that may house battery modules utilizing battery cells having the current collector of the present disclosure.
  • FIG. 3 depicts an embodiment of the first (lithium ion) battery module 28 having battery cells 40 configured in accordance with the present disclosure.
  • the lithium ion battery module 28 depicted in FIG. 3 includes many components that may be common to battery modules configured in accordance with the teachings herein, it should be noted that the illustrated module is provided as an example to facilitate discussion of certain aspects of the present disclosure, and is not intended to exclude the presence of other battery module features (e.g., a battery control module, service disconnects, terminals, and various thermal management features). Further, certain battery modules that utilize battery cells having current collectors of the present disclosure may not include certain of the features described herein.
  • the battery cells 40 each include a first terminal 42 and a second terminal 44 located at a terminal end 46 of the battery cell 40.
  • the terminal end 46 may be considered to be positioned opposite a base end 48 of the battery cell 40, the base end 48 being the end of the battery cell 40 that is located proximate to a base 50 of the lithium ion battery module 28.
  • the terminal end 46 may be part of a lid or cover assembly that encloses a casing 52 of the battery cell 40, and the casing 52 encloses the electrochemical elements of the battery cell 40 (e.g., the electrochemical cell and electrolyte).
  • first and second terminals 42, 44 may be located at different sides of the battery cell 40, such as one at the terminal end 46 and one at the base end 48.
  • Current collectors which are described in further detail below, are located within the casing 52 and electrically couple the electrochemical cell to the first and second terminals 42, 44.
  • the illustrated lithium ion battery module 28 also includes a battery housing 54 (e.g., a lower housing), which couples to the base 50. While shown as separate components, in certain embodiments, the battery housing 54 and the base 50 may be integrally formed (e.g., molded, welded, fabricated) into a single piece into which the battery cells 40 are placed. The battery housing 54 and the base 50 may therefore define a cavity 56 for holding the battery cells 40.
  • the battery housing 54 in general, protects the battery cells 40 from the external environment, and may maintain the position of each battery cell 40 relative to the other battery cells 40.
  • a module cover 58 is placed over the housing 54 to enclose the lithium ion battery module 28.
  • the module cover 58 may house certain components, such as venting mechanisms for the battery module 28, electronics, and so forth. Further, in certain embodiments, the module cover 58 may be coupled to the housing 54 in a different orientation than the orientation illustrated in FIG. 3, depending on various design considerations (e.g., locations of module terminals, venting locations).
  • FIG. 4 is a perspective view of an embodiment of a one-piece current collector 60 (referred to herein as the "current collector 60") coupled to an electrode assembly 62 of one of the battery cells 40.
  • the electrode assembly 62 includes a first electrode (e.g., an anode), and a second electrode (e.g., a cathode).
  • the first and second electrodes each include a foil of conductive material with a corresponding active material coated onto the foil of conductive material. The coating is performed such that ends of the foils are left exposed.
  • the foils may be referred to as an anode fil 64 and a cathode foil 66 of the electrode assembly 62.
  • the first and second electrodes are wound about each other, and a separator is interposed between the first and second electrodes to prevent shorting.
  • the separator is electrically insulative, but is ion-permeable so as to allow ions (e.g., Li ions of an electrolyte) to shuttle between the first and second electrodes.
  • FIG. 4 is an illustration of the battery cell 40 with the casing 52 removed to expose the electrode assembly 62 and the current collector 60.
  • the current collector 60 is a negative current collector configured for attachment to an anode foil 64 (e.g., a first foil) of the electrode assembly 62 and to a negative terminal (e.g., the first terminal 42).
  • another of the current collectors 60 is a positive current collector for attachment to a cathode foil 66 of the battery cell electrode assembly 62 and to a positive terminal (e.g., the second terminal 44).
  • FIG. 5 illustrates a perspective view of the current collector 60 in a folded configuration
  • FIG. 6 illustrates the current collector 60 in a plan view.
  • the current collector 60 is manufactured as a single continuous piece of material.
  • the material may be an electrically conductive material, such as copper or aluminum.
  • the current collector 60 is manufactured in a linear or flat first configuration, but is configured to be folded or bent into a folded second configuration that has a substantially U-shaped
  • the current collector 60 generally includes a first leg 70, a second leg 72, and a connecting portion 74 between the first 70 and second 72 legs.
  • the current collector 60 also includes a transition portion 76 between each leg 70, 72 and the connecting portion 74.
  • the transition portion 76 may be curved, bent, or otherwise form a transition from the connecting portion 74 to the legs 70, 72 in an approximately 90° angle (or other crosswise angle) when the current collector 60 is folded and configured to be attached to a battery cell 40 (for example, as shown in FIG. 4).
  • the first leg 70 is configured to be coupled to a first side of the anode foil 64 (or cathode foil 66) and the second leg 72 is configured to be coupled to a second side of the anode foil 64 (or cathode foil 66).
  • the transition portion 76 may allow the legs 70, 72 to be fit and coupled to a variety of battery cell sizes and shapes.
  • the connection portion 74 may have straight edges or may include one or more notches, gaps, curves, or other configurations that allow the current collector 60 to be coupled to the electrode assembly 62 and the terminal 42 and/or to fit within the casing 52.
  • each of the first 70 and second 72 legs may be said to include a free first end 78 and a second end 80 opposite the first end 78, the second end 80 being where the first 70 and second 72 legs meet the transition portions 76.
  • each transition portion 76 extends from its corresponding leg 70, 72 at an angle.
  • first leg 70 has a longitudinal axis 82A and the corresponding transition portion 76 extends at an angle from the longitudinal axis 82A between the first leg 70 and the connecting portion 76
  • second leg 72 has the same longitudinal axis 82B as the first leg 70 and the corresponding transition portion 76 extends at an angle from the longitudinal axis 82B between the second leg 72 and the connecting portion 76.
  • the connecting portion 76 lies along an axis that is parallel to the longitudinal axis of the first 70 and second 72 legs.
  • the connecting portion 76 has a center point 84 that is offset (disposed a distance away) from the longitudinal axis 82. This configuration can also be seen in the side elevation view of the current collector 60 in FIG. 8.
  • each leg 70, 72 When the current collector 60 is in the folded second configuration, the legs 70, 72 each extend away from the connecting portion 76 in a crosswise manner, for example in an approximately 90° angle.
  • the longitudinal axes of the legs 70, 72 (axes 82A and 82B when the current collector 60 is in the folded second configuration) are parallel and the connecting portion 76 lines in a plane that is orthogonal to, or at least substantially orthogonal to, the longitudinal axis of the first leg 70 and the longitudinal axis of the second leg 72.
  • each leg 70, 72 may also include a bend 90 that facilitates attachment of the current collector 60 to the battery cell 40.
  • the bend 90 may allow the legs 70, 72 to be fit and coupled to a variety of battery cell sizes and shapes.
  • This configuration allows the current collector 60 to meet battery packaging requirements, that is, allows the legs 70, 72 of the current collector 60 to be in contact with the first foil 64 while also allowing the connecting portion 76 to be aligned with and coupled to the first terminal 42.
  • the current collector 60 is configured to be attached to either the first electrode assembly foil 64 and the first terminal 42, or to the second electrode assembly foil 66 and the second terminal 44. It should be understood that a description with respect to connection to the first foil 64 and the first terminal 42 also applies to the second foil 66 and the second terminal 44.
  • the connecting portion 76 also provides an attachment area 92 for attachment between the current collector 60 and the battery terminal 42.
  • the attachment area 92 may have a thickness that is less than a thickness of the adjacent portions of the current collector 60 (for example, as shown in FIGS. 7 and 8). This thinner attachment area 92 allows the weld to pass through the material of the attachment area 92 to the battery terminal 42, such as when a lap weld is used.
  • the attachment area 92 may have a first thickness and the legs 70, 72 may each of a second thickness that is greater than the first thickness.
  • the second thickness may depend on the current carrying capacity of the legs 70, 72 (e.g., as dependent upon expected operating conditions of the battery cell 40) and/or battery packaging requirements.
  • This arrangement advantageously allows the attachment area 92 to be welded to the battery terminal 42 using a power level that will not generate enough heat to damage the seal on the battery terminal 42 that seals the battery terminal 42 to the battery cell casing 52, but still allows for the legs 70, 72 to be thick enough to accommodate the desired power output of the battery cell 40.
  • the legs 70, 72 may be composed of aluminum (Al), and may have a thickness of between approximately 1.0 mm and approximately 1.5 mm, whereas the attachment area 92 may have a thickness of between approximately 0.8 mm and approximately 1.0 mm.
  • the legs 70, 72 may be composed of copper (Cu) and may have a thickness of between approximately 0.8 mm and approximately 1.2 mm, whereas the attachment area 92 may have a thickness of between approximately 0.5 mm and approximately 0.8 mm. In both examples, the attachment area 92 is thinner than the legs 70, 72.
  • the first leg 70 and the second leg 72 are arranged so that the free first ends 78 of the first leg 70 and the second leg 72 diverge from one another as compared with the second ends 80 nearest the connecting portion 76.
  • This allows current collector 60 to be placed over a foil that has a similar shape.
  • the first leg 70 and the second leg 72 are flexible, they can be arranged to be placed over foils of the electrode assembly 62 with varying shapes without concern of breakage during manufacture. Indeed, as shown in the side elevation view of FIG 8 and the underside perspective view of FIG 9, the current collector 60 may have a profile that allows it to connect to various electrode assembly sizes, while also providing a surface for securement to the terminals 42, 44.
  • FIG. 10 shows a cross-sectional view of a point of attachment 100 between the battery terminal 42 and the connecting portion 76 of the current collector 60.
  • the attachment area 92 of the connecting portion 76 is placed on a contact surface 102 of an underside of the battery terminal 42 such that the attachment area 92 is at a location on the contact surface 102 where heat from welding will not melt or otherwise compromise a gasket 104 or other soft material proximate the terminal 42.
  • the gasket 104 may be positioned between the terminal 42 and a terminal assembly lid 106.
  • the current collector 60 may be coupled to the terminal 42 using laser welding.
  • Points of attachment 100 are shown in FIGS. 10-12, and represent welding patterns. The locations of the attachment 100 are generally between the center and the edges of the contact surface 102 of the terminal 42, and far enough away from the edges where a gasket or plastic component may be located.
  • FIGS. 10 and 11 show zigzag-type weld patterns for the points of attachment 100, it will be understood that any suitable pattern or location may be used that will meet current carrying capability requirements and securely couple the current collector 60 to the terminal 42, including linear patterns, hatched patterns, sinusoidal patterns, or the like. For example, as depicted in FIG. 12, the points of attachment 100 may be linear.
  • FIG. 13 an exemplary configuration of a plurality of one- piece current collectors produced during a manufacturing process is shown.
  • a flat piece or sheet of conductive material such as copper or aluminum, may be stamped or cut into the configuration shown in FIG. 13 to simultaneously create a plurality of current collectors.
  • the connecting portions of a plurality of the current collectors 60 are in an uninterrupted elongated portion 110 and extend between a plurality of first legs 70 and second legs 72.
  • the flat piece or sheet of material Once the flat piece or sheet of material has been stamped as shown, it may then be cut to separate the current collectors 60.
  • the separated current collectors 60 can then be bent into the desired shape and welded or otherwise affixed to the contact surface 102 of an underside of the battery terminal 42.
  • One or more of the disclosed embodiments may provide one or more technical effects including the manufacture of a one-piece current collector that can be used in a variety of lithium ion battery cells.
  • the one-piece current collector may be fabricated from a single continuous piece of material in a manner that allows the piece to be folded to produce a shape of the one-piece current collector. Manufacturing the one-piece current collector in this manner may avoid additional manufacturing steps, such as manufacturing steps that involve assembly of the current collector from several pieces.
  • the technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Abstract

L'invention concerne un collecteur de courant (60) destiné à être utilisé dans une cellule de batterie au lithium-ion (40) comprenant une première patte (70), une seconde patte (72) et une partie de liaison (74) entre la première patte (70) et la seconde patte (72) et configuré pour être fixé à une borne (42, 44) de la cellule de batterie au lithium-ion (40). La première patte (70), la seconde patte (72) et la partie de liaison (74) sont toutes fabriquées à partir d'une unique pièce continu de matériau.
PCT/US2018/040943 2017-07-07 2018-07-05 Collecteur de courant monopièce pour cellule de batterie WO2019010323A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201762529798P 2017-07-07 2017-07-07
US62/529,798 2017-07-07

Publications (1)

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WO2019010323A1 true WO2019010323A1 (fr) 2019-01-10

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11916256B2 (en) 2021-02-10 2024-02-27 Medtronic, Inc. Battery assembly

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2000150306A (ja) * 1998-11-12 2000-05-30 Toyota Motor Corp 電池またはキャパシタの集電方式
US8673470B2 (en) * 2010-02-08 2014-03-18 Hitachi Vehicle Energy, Ltd. Secondary cell
US20160079583A1 (en) * 2014-09-11 2016-03-17 Gs Yuasa International Ltd. Energy storage device

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2000150306A (ja) * 1998-11-12 2000-05-30 Toyota Motor Corp 電池またはキャパシタの集電方式
US8673470B2 (en) * 2010-02-08 2014-03-18 Hitachi Vehicle Energy, Ltd. Secondary cell
US20160079583A1 (en) * 2014-09-11 2016-03-17 Gs Yuasa International Ltd. Energy storage device

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11916256B2 (en) 2021-02-10 2024-02-27 Medtronic, Inc. Battery assembly

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